R WORD PROCESSOR SERVICE MANUAL MODEL:DP-525CJ/DP-530CJ/DP-540CJ/DP-550CJ LW-800ic/LW-810ic/LW-810icBL/LW-840ic REVISED EDITION
SERVICE MANUAL CONTENTS PART I THEORY OF OPERATION CHAPTER 1 MECHANICAL THEORY ....................................................................... 1-1 1. Ink Jet Printer ........................................................................................................... 1-1 1.1. 1.2. 1.3. 2. Ink Jet Printer System Configuration .......................................................................... 1-2 Ink Jet Operation ...................................................................
SERVICE MANUAL 3. Power Supply Circuit ................................................................................................ 2-4 3.1. 3.2. 3.3. 4. Reset Circuit............................................................................................................. 2-6 4.1. 5. Configuration............................................................................................................ 2-15 Keyboard System ......................................................................
SERVICE MANUAL 10.3.1. Read/Write Circuit ...................................................................................... 2-26 10.3.2. Motor Drive Circuit...................................................................................... 2-26 10.3.3. Sensor Circuits ........................................................................................... 2-26 PART II REPAIR CHAPTER 3 TROUBLESHOOTING .......................................................................... 3-1 1. 2.
SERVICE MANUAL 7.3.7. 7.3.8. DISK TYPE ................................................................................................ 3-48 RS-232C Test ("Echo Back") ...................................................................... 3-49 CHAPTER 4 COMPONENT DISASSEMBLY............................................................. 4-1 1. Covers...................................................................................................................... 4-1 1.1. 2. Keyboard Assembly ........
SERVICE MANUAL 4. 5. Removing the FDD Assembly ................................................................................ 4-39 Switch PCB ............................................................................................................ 4-40 5.1. 5.2. 6. 7. Removing the Switch PCB ....................................................................................... 4-41 Installing the Switch PCB..........................................................................................
SERVICE MANUAL 2. 3. Replacing the Ink Cartridge ...................................................................................... 6-5 Cleaning the Print Head ........................................................................................... 6-9 3.1. 3.2. 3.3. Cleaning the Print Head Automatically........................................................................ 6-9 Cleaning the Ink Jet Nozzles and Contacts .................................................................
SERVICE MANUAL FIGURES Figure Title Page Fig. 1.1 Ink Jet Printer Assembly ....................................................................................... 1-1 Fig. 1.2 General View of Printing Mechanism .................................................................... 1-3 Fig. 1.3A Paper Feed Mechanism........................................................................................ 1-4 Fig. 1.3B Paper Feed Mechanism................................................................
SERVICE MANUAL Figure Title Page Fig. 2.10 Carriage Motor Drive Circuit................................................................................ 2-12 Fig. 2.11 Line Feed Motor Drive Circuit ............................................................................. 2-13 Fig. 2.12 Carriage Home Position Sensor Circuit ............................................................... 2-14 Fig. 2.13 PE Sensor Detection Circuit ...................................................................
SERVICE MANUAL Figure Title Page Fig. 3.16 Printer Check #2 (in progress) Display................................................................ 3-29 Fig. 3.17 Sample Test Pattern 2........................................................................................ 3-30 Fig. 3.18 Dot Patterns for Print Test #2 (Patterns 1 to 4) ................................................... 3-31 Fig. 3.19 Dot Patterns for Print Test #2 (Patterns 5 and 6) ................................................
SERVICE MANUAL Figure Title Page Fig. 4.15 Fitting LCD Volume Guide to LCD Volume Knob................................................. 4-21 Fig. 4.16 Installing the LCD Lower Cover........................................................................... 4-22 Fig. 4.17 Fitting the Core .................................................................................................. 4-23 Fig. 4.18 Installing the Hinge Assy..........................................................................
SERVICE MANUAL Figure Title Page Fig. 4.47 Switch PCB ........................................................................................................ 4-58 Fig. 4.48 Switch PCB ........................................................................................................ 4-59 Fig. 4.49 Removing the Main PCB..................................................................................... 4-60 Fig. 4.50 Removing the Shield Plate (ESD) ...........................................
THEORY SERVICE MANUAL Mechanical PART I THEORY OF OPERATION CHAPTER 1 MECHANICAL THEORY 1. Ink Jet Printer Fig. 1.
THEORY SERVICE MANUAL Mechanical 1.1. Ink Jet Printer System Configuration The ink jet printer contains the following components: • Carriage assembly • Carriage motion control system • Paper feed mechanism • Maintenance station • Sensors The outline of these components are described below. 1. Carriage Assembly The carriage assembly consists of the carriage and ink cartridge (the cartridge contains the ink jet nozzles).
THEORY SERVICE MANUAL Mechanical Fig. 1.
THEORY SERVICE MANUAL Mechanical 1.2. Ink Jet Operation 1.2.1. Paper Feed Mechanism The paper feed mechanism consist of the paper feed system, paper eject system, and the paper setting system. (1)The paper feed system consists of the ACF shaft gear, separate roller, ACF shaft locker, locker spring, idle gears 1, 2, 3, and 4, PF roller gear, changer lever 1 and 2, spring, and the line feed motor.
THEORY SERVICE MANUAL Mechanical Fig. 1.3B Paper Feed Mechanism (2)The paper eject system consists of the line feed motor, collar, idle gears 1, 5, and 6, PF roller gear, eject roller gear, pressure roller, roller holder, holder plate, pressure roller spring, star wheel holder, and the star wheel. After paper is registered, the paper feed motor is driven in the paper feeding direction (normal rotation) and paper is fed by the PF roller and the pressure roller.
THEORY SERVICE MANUAL Mechanical (3)The paper setting system consists of the hopper, hopper spring, separate pad, collar, paper guide, ACF change lever, change spring, and the ACF change shaft. When inserting a thick paper, the ACF change lever should place at the front position. 24lb Thick Paper Envelope Label Transparency etc. Fig. 1.
THEORY SERVICE MANUAL 1.2.2. Mechanical Carriage Assembly The carriage assembly consists of the carriage and ink cartridge (the cartridge contains the ink jet nozzles). The carriage consists of the head locker and locker spring, the rubber pad, and the flat cable. The flat cable connects to the main PCB. See Fig. 1.6. The printer flat cable must be firmly in contact with the ink jet cartridge for printing to be enabled.
THEORY SERVICE MANUAL Mechanical Fig. 1.
THEORY SERVICE MANUAL Mechanical Fig. 1.
THEORY SERVICE MANUAL Mechanical 1.2.3. Carriage Motion Control All operations related to carriage movement are driven by the CA motor. The CA motor assembly consists of a motor, a timing belt, an idle pulley, and an idle pulley holder and pulley holder spring: the motor and the idle pulley holder are mounted to the CA frame; the belt runs between the motor and the pulley. The pulley holder spring between the idle pulley holder and the CA frame sets belt tension. See Fig. 1.9. Fig. 1.
THEORY SERVICE MANUAL 1.2.4. Mechanical Maintenance Station Operation The maintenance station operation consists of spitting, wiping, capping, and purging. Table 1.1 shows a summary of maintenance operation for various printer states. Table 1.
THEORY SERVICE MANUAL Mechanical 1.2.4.1. Spitting Spitting is performed at machine power-on, after uncapping from the maintenance station to clear dormant nozzles, and during the printing process to ensure that infrequently used nozzles are available when required to print. There must also be spitting after a wipe cycle, except when the printhead is going to the cap position; otherwise wiping causes distorted printing if the wiper has experienced any wear.
THEORY SERVICE MANUAL Mechanical 1.2.4.2. Wiping Wiping of the print head occurs when the cartridge moves across the wiper (in either direction). The printhead is wiped (twice) when power is turned on, when beginning a print job (after the print head has been capped for more than four minutes), after six pages of continuous printing, after 50 seconds of printing on the same page, and after purging or changing the ink cartridge. Fig. 1.
THEORY SERVICE MANUAL Mechanical 1.2.4.3. Capping Capping occurs by the movement of the carriage assembly to the maintenance station, which moves the MS carriage up to the ramp to align the rubber cap with the ink jet nozzles. The rubber cap prevents the ink from drying and causing the printhead to clog. The printer will automatically cap the printhead when the system is powered on, when no data is received for 30 seconds, and after purging or ink cartridge change. Fig. 1.
THEORY SERVICE MANUAL 1.2.5. Mechanical Sensors There are two sensors in the printer assembly: the carriage home position sensor (leaf switch assembly, attached to the right end of the CA frame) and the paper end sensor (attached to the bottom of the PF base at the right rear). 1.2.5.1. Carriage Home Position Sensor Upon power-up of the system or when the carriage is reset, the carriage moves to the right end of the printer assembly and activates the home position sensor (leaf switch assembly).
THEORY SERVICE MANUAL Mechanical 1.2.5.2. PE Sensor PE sensor detects when the trailing edge of the paper passes the knob of PE sensor. PE sensor is 1C-1P Switch (normal open.) See Fig. 1.14. Fig. 1.
THEORY SERVICE MANUAL 1.3. Mechanical INK CHG (Ink Change) Functions There are two operator-initiated printer maintenance functions available from the keyboard: ink cartridge replacement and automatic printhead cleaning (purging). 1.3.1. Ink Cartridge Installation/Replacement There is an ink cartridge installation/replacement function available from the keyboard. Pressing the key combination CODE + INK CHG moves the printhead from the maintenance station to the right end of the printer assembly.
THEORY SERVICE MANUAL Mechanical 2. Keyboard The keyboard assembly consists of the keyboard panel and keys, the FPC (flexible printed circuit) board, and the keyboard base plate. Fig. 1.
THEORY SERVICE MANUAL Mechanical The key tops and key stems are assembled in the keyboard panel. The FPC (flexible printed circuit) board with rubber contacts is fitted to the base plate. See Fig. 1.16. The FPC board is a single sheet of film (FPC) on which an electrode pattern is printed in layers. When the key top is pressed, the key actuator presses the rubber contact; the conductive part of the contact connects both of the electrodes to output the predetermined signal for the key. Fig. 1.
THEORY SERVICE MANUAL Mechanical 3. LCD The LCD (Liquid Crystal Display) module is secured inside the upper cover by the LCD bearing at one end and the hinge assembly at the other end so that it can rotate up and down. From the closed position, the LCD can be tilted up as much as approximately 132°. The hinge assembly is the friction type holder that holds the LCD at whatever angle the user sets within a range approximately 31° from the upright position.
THEORY SERVICE MANUAL Mechanical Fig. 1.
THEORY SERVICE MANUAL Mechanical Fig. 1.
THEORY SERVICE MANUAL Mechanical Fig. 1.
THEORY SERVICE MANUAL Mechanical Fig. 1.
THEORY SERVICE MANUAL CHAPTER 2 1. Electrical ELECTRICAL THEORY System Configuration The major electronic component parts of the machine are shown in Fig. 2.1. 1.1. Main PCB (Printed Circuit Board) The main PCB controls the entire system including the LCD, ink cartridge, and the motors in the printer. The motors and the ink cartridge are driven by +24 VDC, and the CPU and other devices are driven by +5 VDC. 1.2.
THEORY SERVICE MANUAL Electrical Fig. 2.
THEORY SERVICE MANUAL 2. Electrical Ink Jet Printer Configuration The following describes the operation of the ink cartridge, motors and other components. 2.1. Ink Cartridge An ink cartridge contains both ink and the print head which has 56 nozzles and prints at a resolution of 300 dpi. 2.2. Carriage Motor The carriage step motor drives the carriage right and left with precision motion control. 2.3. Line Feed Motor The line feed motor feeds the paper forward and in reverse. 2.4.
THEORY SERVICE MANUAL Electrical 3. Power Supply Circuit 3.1. Configuration Fig. 2.2 shows the power supply circuit. The power supply section converts the unstable input (PWR) supplied from the switch PCB into stable +24 VDC (for motors and print head) and +5 VDC (for logic). A 2-channel switching regulator IC (#4) converts unstable input into stable output. Fig. 2.
THEORY SERVICE MANUAL 3.2. Electrical +24V Generator The timing chart of the +24V generation circuit during idling is shown in Fig. 2.3. Switching Q6 by #4 at 100 kHz boosts the input to a stable +24V. Energy is accumulated in L1 while Q6 is ON and the power is transmitted to the output side by the back electromotive force generated from the moment Q6 is turned OFF. Stabilization to +24V is achieved by changing the ON-OFF duty ratio of Q6. Fig. 2.3 Timing Chart of +24V Generation Circuit 3.3.
THEORY SERVICE MANUAL Electrical 4. Reset Circuit 4.1. Configuration The reset circuit is shown in Fig. 2.5. The reset signal (MRST) used to initialize the system is generated using the leading and trailing edges of the +5V voltage. The reset signal is input to the following devices. Device Pin CBIC (#8) 17 Printer drivers (#2, #3) 5 Fig. 2.
THEORY SERVICE MANUAL Electrical 5. CBIC and Peripherals 5.1. CBIC #8 CBIC (#8) is a Cell-based IC in which logic circuits for controlling peripherals are integrated with the CPU core. With the functions incorporated in it, CBIC (#8) controls all the functions of the system including printer control and control of the LCD display. 5.2. Main ROM (#11, #12) Installation of a maximum of 8 Mbytes (32 Mbits x 2 pcs.) of ROM is possible.
THEORY SERVICE MANUAL Electrical 5.7. Clock Circuit Four different clock circuits shown in Table 2.1 are incorporated in the main PCB. Table 2.1 Clock Circuit Clock Circuit 5.8. Frequency Function 16MHz XT2 is the standard clock for FDD control; it inputs for #5 (pins 25, 26). 18MHz XT1 is the standard clock for FDD control; it inputs for #8 (pin 167). 20MHz XT3 is the standard clock for printer control and other several timing; it inputs for #8 (pints 14, 15). 14.
THEORY SERVICE MANUAL 5.9. Electrical Country Specification Change-over The country specification change-over circuit is shown in Fig. 2.7. The country specification is recognized by the CPU by sensing solder on the solder points. Fig. 2.
THEORY SERVICE MANUAL Electrical 5.10. RS-232C I/F Circuit The RS-232C I/F circuit is shown in Fig. 2.8. The driver IC (#1) converts the signal level (+5V – ±0V) on the main PCB to the RS-232C signal level in the external line and vice versa. Fig. 2.
THEORY SERVICE MANUAL Electrical 6. Printer Control 6.1. Ink Jet Head Control The ink jet head drive circuit is shown in Fig. 2.9. The ink jet head has 50 active nozzles (monochrome). Two addressable multiplexing printer drive circuits (#2, #3) activate the nozzles for printing. Custom circuitry controls the timing and synchronization of ink deposited as the cartridge moves across the paper in printing. The same system controls ink jet head maintenance (spitting into the trough). Fig. 2.
THEORY SERVICE MANUAL Electrical 6.2. Carriage Motor Control The carriage motor control circuit is shown in Fig. 2.10. +24 VDC is supplied to the motor through connector CN3, pin 5. Motor phases A, B, C, and D are driven by the CBIC (#8) through pins 150 - 153, respectively. The outputs of the CBIC turn darlington transistors Q1 - Q4 on and off, which in turn affect the motor phases. Fig. 2.
THEORY SERVICE MANUAL 6.3. Electrical Line Feed Motor Control The line feed motor drive circuit is shown in Fig. 2.11. The line feed motor is powered by +24 VDC. Each of he four phases of the motor is excited when CBIC (#8), via ports LF-A, B, C, and D, outputs to turn on the darlington transistors Q23 - Q26. This provides a path to ground through the transistor, which allows current to flow. When the printer gate array outputs a LOW, the transistor remains off. Fig. 2.
THEORY SERVICE MANUAL Electrical 6.4. Carriage Home Position Sensor The carriage home position sensor circuit is shown in Fig. 2.12. The HIGH/LOW status of the sensor is read by pin 164 of the CBIC (#8). The signal goes LOW when the carriage reaches the home position. Fig. 2.12 Carriage Home Position Sensor Circuit 6.5. PE Sensor The PE sensor detection circuit is shown in Fig. 2.13. The HIGH/LOW status of the PE sensor is read by pin 165 of the CBIC (#8).
THEORY SERVICE MANUAL 7. Switch PCB 7.1. Configuration Electrical The Switch PCB is installed between the AC adaptor and the main PCB to turn the power on and off and protect devices at the occurrence of an alarm, etc. Fig. 2.14 shows the external view of the switch PCB and Fig. 2.15 the switch PCB circuit. Fig. 2.14 External View of the Switch PCB Fig. 2.
THEORY SERVICE MANUAL Electrical 8. Keyboard System 8.1. FPC Operation The keyboard is a flexible printed circuit (FPC) board on which the circuit pattern and electrodes are printed. When a key is pressed, the key stem is forced down until the carbon-type conductive silicone rubber makes a contact with the FPC electrode and electricity is conducted. See Fig. 2.16. Key Actuator Contact Rubber Carbon Electrodes Carbon Silicon Conductive Rubber FPC Board Base Plate Fig. 2.
THEORY SERVICE MANUAL 8.2. Electrical Keyboard Scan Fig. 2.17 shows the pattern from wiring electrodes on the board (this figure shows only simplified wiring for ease of explanation and is slightly different from the actual wiring). Refer to Fig. 2.17 to understand the keyboard scanning operation described. When a key is not pressed, continuity does not exist in any combination of the matrix (e.g. X1 and Y1 or X2 and Y2).
THEORY SERVICE MANUAL Electrical 8.3. Keyboard Control Circuit The keyboard control circuit is shown in Fig. 2.18. The matrix pattern on the keyboard FPC controls port 7 (0:7) of CBIC (#8) according to data signals KO0 through KO8. The LOW level signals are output to output lines KO0 through KO8. The electrode wiring is scanned line by line. The result of scanning is input to P70 through P77 of CBIC (#8). CBIC (#8) detects which key has been pressed. The key matrix given in Fig. 2.
THEORY SERVICE MANUAL Electrical Fig. 2.19 Keyboard Matrix Fig. 2.20 Keyboard Symbols (Corresponding to Keyboard Matrix in Fig. 2.
THEORY SERVICE MANUAL Electrical 9. LCD Module The block diagram of the LCD display operation is shown in Fig. 2.21. CBIC (#8) on the main PCB outputs the LCD module control signals to the LCD module. The LCD drive voltage (VEE) is generated by DC-DC convertor by the pulses output from CBIC (#8). Display data, the data written to the SRAM (#6) that functions as Video RAM is always sent to the LCD module as 4-bit parallel data. Fig. 2.
THEORY SERVICE MANUAL 9.1. Electrical LCD Control The CBIC (#8) controls the LCD control signals and the SRAM access. The display data written to the SRAM (#6) is read by the CBIC (#8) in regular intervals, converted into the 4-bit parallel data by the CBIC (#8) and then sent to the LCD module. Black and white of the display data are inverted by connecting the R55 (#8 REV terminal). Connect the R55 if the transmission type LCD is used.
THEORY SERVICE MANUAL Electrical 9.3. LCD Drive Voltage (VEE) Generation Circuit The polarity of the LCD drive voltage (VEE) differs according to the LCD module. Fig. 2.23 shows the circuit for the LCD module driven by the minus VEE voltage. The +5 VDC source voltage is switched continuously by the 20 kHz pulses from CBIC (#8) to energize L5. The reverse voltage generated by L5 is rectified by D6 and regulated by ZD5. The ZD5 determines the VEE voltage (about -16 V).
THEORY SERVICE MANUAL 9.4. Electrical Power Supply for CFL Backlight The CFL backlight circuit consists of the control circuit that turns ON/OFF the CFL and the inverter PCB. The ON/OFF status of the CFL is controlled by the CFLON terminal of the CBIC (#8). The inverter PCB converts +5V to AC voltage to drive the CFL tube. The type of inverter PCB differs according to the LCD. Fig. 2.25 shows the CFL backlight circuit. Fig.2.
THEORY SERVICE MANUAL Electrical 10. FDD (Floppy Disk Drive) Control 10.1. FDD Configuration The FDD consists of two sections: the FDD controller and the FDD module. The FDD controller circuit controls the contents to be received and stores the data in the FDD module. The FDD module drives the motors, sensors, and magnetic head. The interface signals between the FDD and the FDC are shown in Table below: Table.2.3 FDC(#5) and FDD Module Links (Interface Signals) Signals Read/Write Circuits Pin No.
THEORY SERVICE MANUAL 10.2. Electrical FDD Operation 10.2.1. Basic Operation CBIC(#8) writes commands to FDC(#5), and the FDC(#5) controls the FDD in accordance with these commands and reads/writes data. See Fig. 2.26. 10.2.2. Interface between CBIC (#8) and FDC (#5) If CBIC(#8) accesses an internal register other than the data resister in FDC (#5), the normal read/write operation will be performed.
THEORY SERVICE MANUAL Electrical 10.3. FDD Module The FDD Module is composed of the motor, sensor, magnetic head, and the IC that drives them. The FDD Module is controlled by the FDC (#5) of the MAIN PCB. 10.3.1. Read/Write Circuit In read operation, the circuit amplifies the analog signals picked up by the magnetic head and converts the analog signal to serial digital pulses. The serial pulses are then transmitted to the FDC (#5) and decoded to parallel digital data.
THEORY SERVICE MANUAL Electrical 4. Disk-in Sensor When a disk is inserted in the FDD, this sensor outputs a LOW level signal (HIGH when no disk). The output of the sensor is connected to the controller and sent as a "DISK CHANGE" signal that shows whether a disk is changed; when a disk is changed, the "DISKCHANGE" signal becomes LOW. Once the "DISK CHANGE" signal becomes LOW, it remains low until the "STEP" signal is received from the FDC #5.
REPAIR SERVICE MANUAL Troubleshooting PART II REPAIR CHAPTER 3 TROUBLESHOOTING 1. Introduction This chapter explains troubleshooting procedures for the word processor. Since it is impossible to troubleshoot all instances of a problem, only a limited number of cases are presented. Thorough understanding of the procedures given in each section is essential for efficient troubleshooting, and can provide a good insight to the problem. 2. Precautions 2.1.
REPAIR SERVICE MANUAL Troubleshooting CAUTION: Electrostatic Discharge Hazard Wear an anti-static wrist strap with ground wire to prevent damage to sensitive electronic components. In addition to the usual precautions, such as turning off power before removing circuit boards: • Keep the ESD-sensitive part in its original shipping container (a special "ESD bag") until you are ready to install it.
REPAIR SERVICE MANUAL Troubleshooting • Run the appropriate Self Test operation (from the software) for the suspected problem before attempting any mechanical or electrical troubleshooting. • Supply voltage: Check the AC input voltage and DC supply voltage for all sections. Make sure they meet specified voltage values. • Connectors: Check all connectors and make sure they are tight. • Fuses: Check for blown fuses (F1 and the thermo-fuse inside the AC adapter).
REPAIR SERVICE MANUAL Troubleshooting 5. Troubleshooting Flow Charts Power ON NO LCD operating correctly? Problem No. 1 YES NO Carriage (print head) moves? Problem No. 2 YES NO Printer home position detected? Problem No. 3 YES NO Keys work properly? Problem No. 4 YES NO Prints normally? Problem No. 5 YES NO Linefeeds Feed operates Paper normally? Problem No. 6 correctly? YES A Fig. 3.
REPAIR SERVICE MANUAL Troubleshooting A NO Does the buzzer sound when an invalid key is pressed? Problem No. 7 YES NO Does the LCD operate? Problem No. 8 YES NO Does the LCD display correctly? Problem No. 9 YES Does the unit print when paper is set, or print when no paper is set? NO Problem No. 10 YES NO Does the FDD operate correctly? Problem No. 11 YES Does the fax/modem (optional) Line Feed operates operate properly? correctly? NO Problem No.
REPAIR SERVICE MANUAL Troubleshooting 6. Failure Analysis The following table lists the failure problems for troubleshooting all basic systems. See the Troubleshooting Tables on the following pages for a troubleshooting protocol. Table 3.1 Failure Analysis No Problem 1 Nothing happens when the power is switched on (Nothing appears on the LCD). 2 When the power is switched on, the LCD display operates but the carrier does not return to its home position.
REPAIR SERVICE MANUAL Troubleshooting Troubleshooting Tables 1 Problem: Nothing happens when the power is switched on (nothing appears on the LCD). Points to Check Probable Cause Corrective Action Is (at least) about +16 V present on the output plug if the AC adapter? Defective AC adapter Replace the AC adapter. Is fuse F1 on the Switch PCB OK? Blown fuse Replace the Fuse. Are harnesses CN1 on the Switch PCB properly connected? Harnesses improperly connected. Replace the Switch PCB.
REPAIR SERVICE MANUAL Troubleshooting Points to Check Probable Cause Corrective Action Does the signal level at pin 1 of CN13 remain HIGH when the carriage index switch is closed? Broken wire in the carriage index switch assembly Replace the carriage index switch assembly (after confirming discontinuity). Is the carriage index switch connected to CN13? Incorrect connection Reconnect.
REPAIR SERVICE MANUAL Points to Check Troubleshooting Probable Cause Corrective Action Repair Head locker or spring worn or damaged: dirty, worn, or damaged gold-plated contacts the printer flat cable. Remove the cartridge and clean the contacts on the flat cable in the carriage; Replace the carriage mechanism. Replace spring, head locker, or printer flat cable. Defective wiper Replace wiper. Is the cap worn or loose? Defective cap Replace cap.
REPAIR SERVICE MANUAL Troubleshooting 6 Problem: The line feed (LF) motor does not normally. Points to Check Probable Cause Corrective Action Repair Is the LF motor turning activated ? is it noisy? Defective LF motor Replace LF motor. Are any motor harness wires damaged? Defective motor wiring harness Replace LF motor. Are there binds in the LF motor or gear train? Worn, dirty, damaged, or obstructed gear train, improper gear backlash Clean/remove obstructions. Space motor from gear.
REPAIR SERVICE MANUAL Troubleshooting Points to Check Probable Cause Is the correct voltage (about 25V36V) applied to the LCD on pin 11 of connector CN8 of the Main PCB? (640 × 400 LCD) Incorrect power supply voltage to LCD module Is oscillator XT1 operating correctly? (Use an oscilloscope to check) Defective XT1 or #7 Replace XT1, #7. Do the output pulses from MRD of #8 change? Defective #8 Replace #8. 9 Corrective Action Repair Replace the Main PCB.
REPAIR SERVICE MANUAL Troubleshooting 11 Problem: The FDD does not operate correctly Points to Check Probable Cause Corrective Action Repair Is FDD power harness correctly connected? FDD power harness is not correctly connected. Reconnect. Replace the FDD power harness. Is FDD ribbon cable correctly connected? FDD power cable is not correctly connected. Reconnect. Replace the FDD power cable.
REPAIR SERVICE MANUAL Troubleshooting Points to Check Probable Cause (2) "Incorrect spec!"(when power on) Solder point setting is wrong, or the ROM (#11,#12) is incorrectly mounted. Replace the Main PCB. Set the correct solder point, or replace the ROM. RAM improperly installed (e.g. solder bridge) or defective RAM(#10). Replace the Main PCB. Reinstall/replac e the RAM(#10).
REPAIR SERVICE MANUAL Troubleshooting 7. SELF-TESTS From the Main Menu, two self-test modes are available: 1. Self-Print Press the CODE + SHIFT + RETURN keys. 2. Self-Test Press the CODE + SHIFT + BACKSPACE keys. 7.1. SERIAL NUMBER Input Display The machine prompts you for the unit serial number after the Self-Test mode is accessed, but before the test is started: • From the SELF PRINT screen • From the SELF TEST menu, after selecting a test, of after pressing the "S" key. SERIAL NO.
REPAIR SERVICE MANUAL 7.2. Troubleshooting Self Print Mode (1) From the Main Menu, press CODE + SHIFT + RETURN. The SELF PRINT display appears, with the SERIAL NO. input pop-up screen. (2) Enter the unit serial number and press RETURN (or press RETURN without entering a number). (3) A sum check of the MAIN RAM, MAIN ROM and DICTIONARY ROM is then performed. ***** VIDEO RAM MAIN ROM CG ROM DICTIONARY ROM MAIN RAM SELF PRINT Checking... Checking... Checking... Checking... Checking... ***** OK. OK.
REPAIR SERVICE MANUAL Troubleshooting • The following printing pattern is printed: LM 1 inch RM 6.4 inches [Memory Codes 21(H) to 7E(H) printed] • • The serial number is printed on the first line (if it was entered), and then 59 lines of characters are printed at 64 characters per line; with each line beginning with one character from the right of the previous line.
REPAIR SERVICE MANUAL Troubleshooting Fig. 3.
REPAIR SERVICE MANUAL Troubleshooting 7.3. Self-Test Mode There are six tests types available in Self Test mode: (1) LCD Display tests, (2) Printer Checks, (3) Keyboard Test, (4) FDD Tests, (5) PE (Paper Exist), (6) CR (Carriage Reset to Home Position), and (7) RS-232C Test. (1) From the Main Menu, press the CODE + SHIFT + BACKSPACE keys, and the menu shown below displays.
REPAIR SERVICE MANUAL Troubleshooting NOTES: • Pressing the CANCEL key while the above menu is displayed will return the display to the Main Menu.
REPAIR SERVICE MANUAL Troubleshooting 7.3.1. Display (LCD) Test There are four display checks available: 1) CHECK, 2) CROSS, 3) BLACK, and 4) DISP. Q. 5) SLANT LINE (1) From the Self Test menu, select "1" to open the LCD Test Menu. (2) Press the number key for the desired display test. The screen displays the selected test pattern. <14-line model and 10 inch VGA model> ***** LCD TEST MENU ***** 1. CHECK 2. CROSS 3. BLACK 4. DISP. Q 5. SLANT LINE Please select the number. Press CANCEL to finish.
REPAIR SERVICE MANUAL Troubleshooting 7.3.1.1. Check Test The CHECK test displays every other bit as shown below (magnified). Select "1" from the MENU screen. NOTE: • Press the space bar and the displayed bit pattern is reversed. 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Fig. 3.
REPAIR SERVICE MANUAL Troubleshooting 7.3.1.2. Cross Test The CROSS test displays the grid pattern shown below (magnified). Select "2" from the MENU screen. NOTE: • Press the space bar and the displayed bit pattern is reversed. 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Fig. 3.
REPAIR SERVICE MANUAL Troubleshooting 7.3.1.3. Black Test The BLACK test checks for missing dots (pixels). Select "3" from the MENU screen. NOTE: • Press the space bar and the displayed bit pattern is reversed. Every pixel on the screen is displayed. Fig. 3.
REPAIR SERVICE MANUAL Troubleshooting 7.3.1.4. Display Q Test The DISP Q test displays the character "Q" on the entire screen. Select "4" from the MENU screen. NOTE: • Press the space bar and the displayed bit pattern is reversed. 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Fig. 3.
REPAIR SERVICE MANUAL Troubleshooting 7.3.1.5. Slant Line Test The SLANT LINE test displays the pattern as shown below. Select "5" from the MENU screen. The following screen is displayed. Upper left corner NOTE: • Press the space bar and the displayed bit pattern is reversed. • If any key other than the key indicated above is pressed, the screen will return to the MENU screen. Fig. 3.
REPAIR SERVICE MANUAL Troubleshooting 7.3.2. Print Checks There are two self-test print checks. 7.3.2.1. Print Test Pattern 1 Purpose: To check that all characters are printed correctly. From the Self Test menu, select "2" at the MENU screen. When printing is complete, the display automatically return to the Self Test menu. The diagram (see in Fig. 3.14) shows which characters should be printed and their locations in reference to each other. A sample of the printed pattern is shown in Fig. 3.15.
REPAIR SERVICE MANUAL Troubleshooting 0.5 inch SERIAL NO.: XXXXXXXXX (9 digits) 1/6 inch The 20(H) to EF(H) characters are printed on this line (12 point). Line 1 YELLOW * Line 2 MAGENTA * Line 3 CYAN * 1/6 inch The 20(H) to EF(H) characters are printed on this line (7 point). RED* 1/6 inch The 20(H) to 5F(H) characters are printed on this line (18 point). GREEN* BLUE 1/6 inch 1/6 inch A 12 point hyphen is printed 10 times on each of 26 lines here. This group prints in black.
REPAIR SERVICE MANUAL Troubleshooting NOTE: The print format settings are as follows: Font: Type/Style: Line space: Left/right margins: Brougham Normal (12 point/7 point); Bold (18 point) Auto 1.0 − 7.4 inches Yellow Yellow Magenta Cyan Yellow Black Blue Fig. 3.
REPAIR SERVICE MANUAL Troubleshooting 7.3.2.2. Print Test Pattern 2 Purpose: To check that all characters are printed correctly. From the Self Test menu, select "3" at the MENU screen. When printing is complete, the display automatically return tot he Self Test menu. A sample of the printed pattern is shown in Fig. 3.17. ***** PRINTER CHECK ***** Press CANCEL to go to MENU. Fig. 3.16 Printer Check #2 (in progress) Display NOTES: • A paper check is performed before printing.
REPAIR SERVICE MANUAL Troubleshooting Pattern 3 Pattern 1 Pattern 4 14 Pattern 2 31 49 Pattern 5 32 36 XXXXXXXXX (9 digits) 9 Pattern 6 Fig. 3.
REPAIR SERVICE MANUAL Troubleshooting 7.3.2.3. Dot Patterns The following dot (print) patterns correspond to the print test #2 pattern result on the previous page. See also Fig. 3.17 for the location of each dot pattern type. Fig. 3.
REPAIR SERVICE MANUAL Troubleshooting Fig. 3.
REPAIR SERVICE MANUAL 7.3.3. Troubleshooting Keyboard Tests Keyboard inspection checks that the key are making proper contact. There are three keyboard self-tests. (1) Select "4", "5", or "6" from the Self Test menu. If a serial number has not been input before starting the test, the pop-up window will prompt for the serial number; either enter the serial number, or press RETURN to start the test. The display in Fig. 3.20 below indicates that the keyboard test mode has been established.
REPAIR SERVICE MANUAL Troubleshooting (2) To run Test "4" (all keys in Fig. 3.21, "A") a) Starting from the top left of the keyboard, press each key in turn (see sequence below). b) Then press SHIFT + Z, SHIFT + /, and CODE + SPACE. If there is no problem, the message "KB TEST OK" will be printed, and the display will return to the SELF Test menu. Sequence Test Keys NOTES: • After automatic carriage return, "KB TEST OK." prints, and the display returns to the SELF Test menu.
REPAIR SERVICE MANUAL Troubleshooting (4) To run Test "6" (all keys in Fig. 3.21, "A" and "B") a) Starting from the top left of the keyboard, press all keys ("A" & "B") in the sequence indicated below. b) Then press SHIFT + Z, SHIFT + /, and CODE + SPACE. If there is no problem, the message "KB TEST OK" will be printed, and the display will return to the SELF Test menu.
REPAIR SERVICE MANUAL Troubleshooting 7.3.4. FDD Tests There are five tests of the FDD: 1. FDD Test ("7") - checks disk switch, write protect switch, and read/write errors. 2. Special FDD Test ("8") - checks disk type, write protect switch, and read/write. 3. FDD Switch Test ("9") - checks disk switch and write protect switch. 4. FDD Error Rate Check ("D") - checks for disk writing errors. 5. FDD Error Rate Check ("E") - checks for disk reading errors. 7.3.4.1.
REPAIR SERVICE MANUAL Troubleshooting NOTES: • If a key other than the RETURN key is pressed, an error will occur. • A paper check is performed before printing. If paper is set, the print test is executed; if no paper is set, the ERROR pop-up window is displayed. If you select to continue printing, paper is automatically inserted by the ACF and to execute the print test. • After completing the disk drive test, the carriage automatically returns and the test result is printed: SERIAL NO.
REPAIR SERVICE MANUAL Troubleshooting (3) When the direction "Insert write protected disk" is displayed, insert a write- protected diskette in the disk drive (if the disk is not write-protected, an error will occur). The display changes to the following: ***** SPECIAL FDD TEST ***** Change to test disk. Fig. 3.
REPAIR SERVICE MANUAL Troubleshooting NOTES: • After completing the disk drive test, the carriage automatically returns and the test result is printed: • SERIAL NO.
REPAIR SERVICE MANUAL Troubleshooting Table 3.3 FDD Special Test Error Codes ERROR NO.
REPAIR SERVICE MANUAL Troubleshooting 7.3.4.3. FDD SW Test (1) Without a diskette in the disk drive, select "9" from the Self Test menu. If a serial number has not been input before starting the test, the pop-up window will prompt for the serial number; either enter the serial number and press RETURN, or press RETURN to start the test. The display as shown below appears: ***** SPECIAL FDD TEST ***** Insert write protected disk. Fig. 3.
REPAIR SERVICE MANUAL Troubleshooting 7.3.4.4. FDD Write Error Rate Check (1) Without a diskette in the disk drive, select "D" from the Self Test menu. (If a serial number has not been input before starting the test, the pop-up window will prompt for the serial number; either enter the serial number and press RETURN, or press RETURN to start the test.) The display as shown below appears: ***** FDD ERROR RATE CHECK WRITE CHECK ERROR PASS NO. TRACK NO. ***** TIMES Insert disk and press RETURN.
REPAIR SERVICE MANUAL Troubleshooting NOTES: • If an error occurs during checking, PASS NO. and TRACK NO. are printed, and 1 is added to the counter "WRITE CHECK ERROR XXX TIMES.
REPAIR SERVICE MANUAL Troubleshooting 7.3.4.5. FDD Read Error Rate Check (1) Without a diskette in the disk drive, select "E" from the Self Test menu. If a serial number has not been input before starting the test, the pop-up window will prompt for the serial number; either enter the serial number and press RETURN, or press RETURN to start the test. The display as shown below appears: ***** FDD ERROR RATE CHECK READ CHECK ERROR PASS NO. TRACK NO. ***** TIMES Insert disk and press RETURN.
REPAIR SERVICE MANUAL Troubleshooting NOTES: • If an error occurs during checking, PASS NO. and TRACK NO. are printed, and 1 is added to the counter "READ CHECK ERROR XXX TIMES.
REPAIR SERVICE MANUAL Troubleshooting 7.3.5. PE (Paper-End) Sensor Test The PE test checks that the PE sensor is working properly by verifying if paper is set of not. (1) From the Self Test menu, press "A". The display changes to the following: ***** TEST START ***** PAPER EMPTY Press CANCEL to go to MENU. Fig. 3.
REPAIR SERVICE MANUAL 7.3.6. Troubleshooting CR (Carriage Reset) Test The CR test checks the carriage home position. (1) From the Self Test menu, press "B". The following display appears: ***** THE MODE TO ADJUST FOR THE HOME POSITION OF CR CR PHASE HP SENSOR ***** OFF OFF UP ARROW KEY – Turn CR motor on with 'AB' phase. DOWN ARROW KEY – Turn CR motor off. LEFT ARROW KEY – Move CR by 1 step in backward direction. RIGHT ARROW KEY – Move CR by 1 step in forward direction.
REPAIR SERVICE MANUAL Troubleshooting 7.3.7. DISK TYPE The DISK TYPE item on the Self Test menu toggles between 2DD and 2HD (used for specifying which type of disk is used in FDD tests). Press "T" from the Self Test menu to change the DISK TYPE from 2DD to 2HD, as appropriate. ***** DISPLAY PRINTER KEYBOARD FDD PE CR RS-232C SERIAL NO. DISK TYPE. SELF TEST MENU ***** 1 2, 3 4, 5, 6 7, 8, 9, D, E A B C S [ ] T 2DD Please select the number. Press CANCEL to finish. Fig. 3.
REPAIR SERVICE MANUAL 7.3.8. Troubleshooting RS232C The RS232C test executes the echo-back test for all models except DP-525CJ and LW800ic. (1) Test procedure From the Self Test menu, press "C". The following display appears and the RC232C echo-back test starts. Once the test starts, the operation instructions given on the display show the procedure to follow. ***** RS-232C TEST ***** Working Fig. 3.
REPAIR SERVICE MANUAL Troubleshooting 3) Connect the connector for echo-back test and press RETURN. The echo-back test is executed in the following order: 1 Tests the following : CTS = LOW and CD = LOW if RTS = LOW CTS = HIGH and CD = HIGH if RTS = HIGH 2 Tests the following: DSR = LOW if DTR = LOW DSR = HIGH if DTR = HIGH 3 Tests that the data* sent to TXD can be received at RXD correctly. * As the test data, 00(H), FF(H), 55(H), and AA(H) are sent.
REPAIR SERVICE MANUAL 2 Troubleshooting Upper digit = B An error has occurred in the DTR → DSR test executed whie the terminal is open. The lower digit expresses the status by bits. • Bit 0 = 0: DSR = HIGH when DTR = LOW Bit 0 = 1: DSR = LOW when DTR = LOW (error) • Bit 1 = 0: DSR = HIGH when DTR = HIGH Bit 0 = 1: DSR = LOW when DTR = HIGH (error) 3 Upper digit = C An error has occurred in the TXD → RXD test executed while the terminal is open. The data sent to TXD is received at RXD.
REPAIR SERVICE MANUAL Troubleshooting 2) The test connector to be used in the echo-back test is indicated below.
REPAIR SERVICE MANUAL CHAPTER 4 1. Mechanical COMPONENT DISASSEMBLY Covers NOTE: • All model details may not be represented in all illustrations herein. Fig. 4.
REPAIR SERVICE MANUAL Mechanical Many of the parts are held in place by plastic latches which may break if mishandled. To remove such parts, press the hook end of the latch away from the part to which it is latched. 1.1. Upper Cover 1.1.1. Removing the Upper Cover (1) Turn off the power switch. (2) Unplug the AC adaptor from the wall outlet, and unplug the adaptor from the machine.
REPAIR SERVICE MANUAL Mechanical Fig. 4.
REPAIR SERVICE MANUAL Mechanical (4) Remove the top cover: NOTE: • The top cover fits on tabs on the upper cover. a) Open the top cover to about 90°. b) Push on the point indicated by the black arrow and disengage the top cover from the upper cover. Slide the top cover to the right and lift the upper cover clear of the top cover. Fig. 4.
REPAIR SERVICE MANUAL Mechanical (5) Remove the upper cover: a) Move the ink cartridge to the center position. b) Remove the two upper cover taptites at the rear of the machine. Fig. 4.4 Removing the Upper Cover c) Unsnap the right and left retaining tabs inside the upper cover. d) Disengage the LCD latch from the upper cover and tilt the LCD to its upright position.
REPAIR SERVICE MANUAL Mechanical e) Pry up the front of the upper cover and release the twelve retaining locks that secure the upper cover to the bottom cover. f) Raise the upper cover slightly to obtain access and disconnect the LCD harness from the main PCB. NOTE: • For European backlit models, also disconnect the backlight PCB harness from the main PCB. g) Release the four retaining locks at the rear and remove the upper cover from the bottom cover. Remove the upper cover from the bottom cover.
REPAIR SERVICE MANUAL 1.1.2. Mechanical Installing the Upper Cover Electro-Static Discharge Hazard Wear an anti-static wrist strap with ground wire to prevent damage to sensitive electronic components. (1) Install the LCD unit into the upper cover: NOTE: • For the procedure for installing the LCD unit into the upper cover, refer to item (2) in 2.2 "Installing the LCD". (2) While holding the upper cover assembly over the machine, connect the LCD harness to the main PCB.
REPAIR SERVICE MANUAL Mechanical 2. LCD Module 2.1. Disassembling the LCD Module The LCD unit consists of the LCD upper cover, LCD PCB, LCD lower cover, LCD latch, and the LCD plate etc. (1) Remove the LCD unit from the upper cover: a) Place the upper cover on the table with the LCD screen facing down. b) Remove the two screws that secure the hinge assy to the upper cover and remove the hinge assy from the upper cover.
REPAIR SERVICE MANUAL Mechanical Fig. 4.
REPAIR SERVICE MANUAL Mechanical (2) Remove the LCD lower cover: a) Remove the LCD rubber LR (2 pcs.). b) Remove the LCD spacers: LCD spacer M (1 pc.) and LCD spacer LR (2 pcs.). c) Remove the seven taptites and one screw that secure the LCD lower cover to the LCD upper cover. The LCD lower cover can now be removed. Fig. 4.
REPAIR SERVICE MANUAL Mechanical (3) Remove the LCD PCB: Electro-Static Discharge Hazard Wear an anti-static wrist strap with ground wire to prevent damage to sensitive electronic components. a) Place the LCD on the table with the LCD screen facing down. b) Remove the LCD PCB. The procedure to remove the LCD PCB varies according to the model.
REPAIR SERVICE MANUAL Mechanical Fig. 4.
REPAIR SERVICE MANUAL Mechanical Fig. 4.
REPAIR SERVICE MANUAL Mechanical Fig. 4.
REPAIR SERVICE MANUAL Mechanical Fig. 4.
REPAIR SERVICE MANUAL Mechanical Fig. 4.
REPAIR SERVICE MANUAL Mechanical (3) Remove the LCD latch and LCD plate: a) Slide the latch shafts outwards and remove the LCD latch from the LCD upper cover. b) Remove the taptites (2 pcs.) and the LCD plate from the LCD upper cover. Fig. 4.
REPAIR SERVICE MANUAL Mechanical 2.2. Reassembling the LCD Module Electro-Static Discharge Hazard Wear an anti-static wrist strap with ground wire to prevent damage to sensitive electronic components. (1) Install the LCD latch and the LCD plate: a) Place the LCD plate on the LCD upper cover by aligning the holes in the LCD plate with the bosses on the LCD upper cover. Then, secure the LCD plate by tightening the taptites (2 pcs.). b) Mount the LCD latch in the LCD upper cover.
REPAIR SERVICE MANUAL Mechanical Fig. 4.
REPAIR SERVICE MANUAL Mechanical (2) Fit the LCD PCB into the LCD upper cover: a) While holding the inverter PCB at an angle of 45°, slide its edge into hooks b. Then, fit the inverter PCB into the LCD upper cover by prying hook a outwards. The Inverter PCB is held in place by hook a and hooks b. NOTE: • The inverter PCB is installed only in LW-810icBL and DP-550CJ/LW-840ic. b) The procedure to install the LCD PCB differs according to the model.
REPAIR SERVICE MANUAL Mechanical Fig. 4.
REPAIR SERVICE MANUAL Mechanical Adjust the position of the LCD PCB by aligning the holes in the LCD PCB with the bosses on the LCD upper cover. Tighten the screws to secure the LCD PCB in place. c) Return the LCD harness to its original position (3) Install the LCD lower cover: a) Place the LCD lower cover on the LCD upper cover. b) Place the assembly of the LCD lower cover and upper cover on the table with the LCD screen facing up.
REPAIR SERVICE MANUAL Mechanical (4) Install the LCD module in the upper cover: a) Pass the LCD module harness through the hole in the upper cover. b) Fit the LCD module into the LCD upper cover. c) Pass the LCD module harness through the hole in the LCD bearing. Insert the LCD bearing into the holes in the upper cover and the LCD module and secure it with the taptites (2 pcs.). d) Insert the hinge assy into the holes in the upper cover and the LCD module (LCD plate) tighten the screws (2 pcs.
REPAIR SERVICE MANUAL Mechanical Fig. 4.
REPAIR SERVICE MANUAL 3. Mechanical Keyboard Assembly Electro-Static Dischrge Hazard Wear an anti-static wrist strap with ground wire to prevent damage to sensitive electronic components. 3.1. Removing the Keyboard (1) Turn off the power and unplug the power cord. (2) Remove the sub paper support, paper support, top cover, and the upper cover.
REPAIR SERVICE MANUAL Mechanical 3.2. Installing the Keyboard Place the keyboard in the bottom cover on the keyboard supports, plug the keyboard PCB harness into the main PCB, and push down on each side of the keyboard to snap it into place. Fig. 4.
REPAIR SERVICE MANUAL Mechanical 4. Carrying Handle 4.1. Removing the Carrying Handle (1) Stand the machine on its rear side with the underside facing you. (2) Turn the carrying handle perpendicular to the bottom cover. (3) While pushing the carrying handle to the left, press in on the right stopper with a small screwdriver to disengage the handle pivot shaft from the stoppers. (4) Slide the handle fully to the left to clear the locks in the bottom cover, and pull it toward you. 4.2.
REPAIR SERVICE MANUAL Mechanical 5. Ink Jet Printer Assembly The ink jet printer assembly consists of the PF unit, CA unit, and the earth spring. The ink jet printer assembly is secured to the rear of the bottom cover by two screws. Fig. 4.
REPAIR SERVICE MANUAL 5.1. Mechanical Removing the Printer Assembly (1) Remove the upper cover assembly. See steps (1) to (5) in 1.1.1 "Removing the Upper Cover". (2) Unplug the six connectors from the main PCB. Unplug the connectors of the following cables and harnesses: 1) Two flat cables (to carriage) 2) Leaf switch harness 3) PE sensor harness 4) PF motor harness 5) CA motor harness NOTE: • Remove harnesses 2), 3), and 4) from the harness retainers in the bottom cover.
REPAIR SERVICE MANUAL Mechanical 5.3. Disassembling the Printer Assembly Fig. 4.
REPAIR SERVICE MANUAL 5.3.1. Mechanical Removing the CA Unit (1) Remove the earth spring. (2) Remove the two screws from the CA unit. (3) Lift the CA unit to clear it from the catches in the PF unit. 5.3.2. Installing the CA Unit (1) Hold both ends of the CA unit and slide it in so that the alignment ribs on both sides of the CA unit engage in the catch of the PF unit. (2) Secure the CA unit to the PF unit by tightening the screws (2 pcs.). (3) Fit the earth spring.
REPAIR SERVICE MANUAL Mechanical 5.3.3. Disassembling the PF Unit This section describes the procedure for disassembling the PF unit. Fig. 4.
REPAIR SERVICE MANUAL Mechanical 5.3.3.1. Removing the Form Remove the screw and the spacer, then take out the form. Fig. 4.
REPAIR SERVICE MANUAL Mechanical 5.3.3.2. Removing the Release Lever and Release Shaft (1) Remove the release spring. (2) After disengaging the release shaft from the PF base assembly by lightly pushing the leaf spring, slide the release shaft in the thrust direction and align the recess in the release shaft with the cutout in the PF base assembly. Remove the release shaft from the PF base assembly. (3) Turn the release lever clockwise and remove it from the PF base assembly. Fig. 4.
REPAIR SERVICE MANUAL Mechanical 5.3.3.3. Removing the ACF Shaft Assembly (1) Remove the locker spring. (2) Turn the ACF shaft locker clockwise and remove it from the PF base assembly. (3) After disengaging the ACF shaft assembly from the PF base assembly by lightly pushing the leaf spring, slide the ACF shaft assembly in the thrust direction and align the recess in the ACF shaft assembly with the cutout in the PF base assembly. Remove the ACF shaft assembly from the PF base assembly. Fig. 4.
REPAIR SERVICE MANUAL Mechanical 5.3.3.4. Removing the Pressure Rollers and Roller Holders There are four pressure rollers used in the machine and the same removal procedure can be used for all of them. (1) Remove the pressure roller springs (spring A and springs B). (2) Disengage a roller holder from a holder plate and take away the holder plate upward with a roller in it. (3) Push the pressure roller to the cut-out side in the roller holder to remove it from the roller holder. Fig. 4.
REPAIR SERVICE MANUAL Mechanical 5.3.3.5. Removing the Holder Plate (1) Unsnap the two hooks in the PF base assembly to disengage the holder plate from the PF base assembly. Then, lift the holder plate away from the PF base assembly upward by tilting it towards you. (2) Remove the screw and then the ACF shaft stopper. Fig. 4.
REPAIR SERVICE MANUAL Mechanical 5.3.3.6. Removing the Hopper Assembly (1) Unsnap the hook at the left side of the hopper assembly to disengage it from the PF base assembly. Turn the hopper assembly until the oval pin of the PF base assembly is aligned with the cut-out in the hopper assembly fitting hole. Lift the hopper assembly away from the PF base assembly. (2) Remove the hopper springs. (3) Remove the change spring.
REPAIR SERVICE MANUAL Mechanical Fig. 4.
REPAIR SERVICE MANUAL Mechanical 5.3.3.7. Disassembling the Paper Feed Assembly (1) Remove the spring. (2) Remove idle gear 4. (3) Remove the eject roller gear. (4) Remove E ring 3. (5) Remove idle gears 1, 5, and 6. (6) Remove the change lever 1 assembly (changer lever 1, idle gear 3, and spring washer). (7) Remove idle gear 2. (8) Remove the change lever 2 assembly (change lever 2, idle gear 3). (9) Remove the PF roller gear. Fig. 4.
REPAIR SERVICE MANUAL Mechanical 5.3.3.8. Removing the Eject Roller Assembly and the PF Roller Assembly After releasing the hook in the ejector roller assembly, slide it to the right to remove it from the PF base assembly. After releasing the E rings from the PF roller assembly, slide it to the right to remove it from the PF base assembly. Fig. 4.
REPAIR SERVICE MANUAL Mechanical 5.3.3.9. Removing the Motor Frame Assembly (1) Remove the spring R. (2) Remove the two taptites (3x10, 3x20) to remove the motor frame assembly from the PF base assembly. (3) Remove the screw (3x5) to remove the PF motor from the PF motor frame assembly. Fig. 4.
REPAIR SERVICE MANUAL Mechanical 5.3.3.10.Removing the PF Stopper (1) Unsnap the hook on the PF base assembly by pushing it with a screwdriver from the rear of the PF base assembly and the PF stopper is forced upward by spring force. Turn the PF stopper to align the cut-out in the PF stopper bearing with the oval pin of the PF base assembly. Remove the PF stopper from the PF base assembly. (2) Remove the stopper spring. Fig. 4.
REPAIR SERVICE MANUAL Mechanical 5.3.3.11.Removing the PE Sensor (1) Unsnap the hook on the PE sensor by pushing it from the top side of the `F base assembly to disengage it from the PF base assembly. Remove the PE sensor by sliding it towards you. (2) Disconnect the sensor harness connector from the PE sensor. Fig. 4.
REPAIR SERVICE MANUAL 5.3.4. Mechanical Disassembling the CA Unit This section describes the procedure for disassembling the CA unit. Fig. 4.
REPAIR SERVICE MANUAL Mechanical 5.3.4.1. Removing the Carriage The outline of the printer mechanism is shown in Fig. 4.37. The procedure for removing the carriage is explained below. (1) If necessary, remove the ink cartridge and store it in a safe place. (2) Loosen the idle pulley holder screw and remove the idle pulley holder spring to remove the timing belt from the idle pulley. (3) Remove the screw from the main shaft stopper and remove the main shaft stopper.
REPAIR SERVICE MANUAL Mechanical Fig. 4.
REPAIR SERVICE MANUAL Mechanical 5.3.4.2. Removing the Carriage Drive (1) Remove the idle pulley holder screw, the idle pulley and the idle pulley holder; to remove the idle pulley holder, slide it to the right then pull it up. (2) Remove the CA motor screw, then remove the CA motor by turning the CA motor in order to disengage the CA motor flange from the hook on the CA frame.
REPAIR SERVICE MANUAL Mechanical 5.3.4.3. Removing the Star Wheel Holder Assembly (1) Push downward on either of the two hooks on the star wheel holder assembly, and push the star wheel holder forward to disengage the hook from the CA frame. (2) Disengage the other hook in the same manner as described in step (1) above. (3) Push the star wheel holder assembly forward to remove it from the CA frame.
REPAIR SERVICE MANUAL Mechanical 5.3.4.4. Removing the MS Holder Assembly (1) Remove the MS holder assembly screw. (2) Slide the MS holder to clear the hook and remove it from the CA frame. Fig. 4.
REPAIR SERVICE MANUAL Mechanical 5.3.4.5. Removing the Leaf Switch (Home Position Sensor) (1) Remove the leaf switch screw and remove the leaf switch assembly with the cover from the CA frame. (2) Remove the leaf switch assembly from the leaf switch cover. NOTE: • When reassembling the leaf switch, first fit the leaf switch cover on the leaf switch so that the alignment pin on the leaf switch assembly fits correctly into the alignment hole in the leaf switch cover.
REPAIR SERVICE MANUAL Mechanical 5.3.4.6. Removing and Mounting the KB Switch Assy The switch in the KB switch assy is used for the following specifications. • Belgium • Switzerland • Canada Remove the screw from the CA frame and remove the KB Switch Assy. Fig. 4.
REPAIR SERVICE MANUAL 5.4. Mechanical Adjusting the CA Unit NOTE: • Any time the CA motor or the timing belt is removed or replaced, the carriage friction and home position should be checked and adjusted as required. Perform the following adjustments with an ink cartridge installed. Electro-Static Discharge Hazard Wear an anti-static wrist strap with ground wire to prevent damage to sensitive electronic components. 5.4.1.
REPAIR SERVICE MANUAL Mechanical (8) Check the carriage motor "jumping" phase: 5.4.2. a) With the CR test still active, press the UP arrow key to turn the motor on. b) Step the motor right with the RIGHT arrow key until the carriage moves to the rightmost position and then "jumps" (moves) back to the left one step. c) Verify that the motor phase at the "jumping" point is "CD", "D", or "DA" only.
REPAIR SERVICE MANUAL Mechanical (6) Repeat the test with the friction meter (push-pull gauge) to verify that the cartridge friction (belt tension) is within the acceptable range. NOTE: • If adjustment is not satisfactory and the carriage friction is still larger than the acceptable limit, lubricate the idle pulley shaft and idle pulley rotation point. See Lubrication in Chapter 5 "MAINTENANCE" for details. Fig. 4.
REPAIR SERVICE MANUAL Mechanical Fig. 4.
REPAIR SERVICE MANUAL 6. Mechanical Removing the FDD Assembly (1) Remove the FDD flat cable from the Main PCB. (2) Unplug the power cable from the FDD. (3) Remove the two screws securing the FDD to the bottom cover. The two ground plates secured on the FDD are also removed. (4) Move the FDD to the left to clear the retainers in the bottom cover, and lift it out. Fig. 4.
REPAIR SERVICE MANUAL Mechanical 7. Switch PCB Electro-Static Discharge hazard Wear an anti-static wrist strap with ground wire to prevent damage to sensitive electronic components. As shown in Fig. 4.47, the switch PCB is mounted on the bottom cover. Fig. 4.
REPAIR SERVICE MANUAL 7.1. Mechanical Removing the Switch PCB (1) Unplug the power harness from the main PCB. (2) Remove the screw securing the switch PCB switch section, slide it to the right and up to clear the switch housing, and lift it out. 7.2. Installing the Switch PCB (1) Place the switch PCB switch section into its location in the bottom cover, slide it to the left and down to insert the switch in its housing, and secure it in replace with the screw.
REPAIR SERVICE MANUAL Mechanical 8. Removing the Main PCB Electro-Static Discharge Hazard Wear an anti-static wire strap with ground wire to prevent damage to sensitive electronic components. Be sure to hold the connector - not the cable - when connecting or disconnecting a harness. The main PCB is fitted to the bottom cover and secured by screws. Remove the screws, and all harnesses and cables from the main PCB, and lift it out of the bottom cover.
REPAIR SERVICE MANUAL 9. Mechanical Removing the Shield Plate (ESD) Lift up on the rear side of the shield plate to clear the alignment pin, slide the shield plate forward to clear the three retaining clips in the bottom cover, and lift it out. Fig. 4.
REPAIR SERVICE MANUAL CHAPTER 5 Mechanical MAINTENANCE 1. Lubrication 1.1. Lubricants Table 5.1 Recommended Lubricants Symbol E Epinoc grease #1 S1 Silicone grease G-501 S2 Silicone grease KS64F SO Silicone oil KF96 T 1.2. 1.3. Lubricant FBK Turbin#32 Precautions 1. Lubricate carefully so that the oil or grease will not stick to places other than the specified points; otherwise, the plastic parts and electronic boards will be adversely affected. 2.
REPAIR SERVICE MANUAL Mechanical Fig. 5.
REPAIR SERVICE MANUAL Mechanical Fig. 5.
REPAIR SERVICE MANUAL Mechanical Fig. 5.
REPAIR SERVICE MANUAL 2. Mechanical Replacing the Ink Cartridge WARNING: The bottom of the ink jet cartridge is covered with wet ink. Avoid contact of ink with skin and clothing. Ink may cause irritation especially to the eyes. The machine uses a replaceable ink jet cartridge that contains both the print head and ink. It should be replaced after about 1,000,000 characters (estimated using normal text, 12 point, Brougham font). (1) Open the paper support and the top cover.
REPAIR SERVICE MANUAL Mechanical Fig. 5.
REPAIR SERVICE MANUAL Mechanical (4) After making sure that the carriage has returned to the home position, return the LCD module in the close position. (5) Grasp the ink jet cartridge as shown below and push it backward until a click of release is heard; then pull the cartridge straight up and out of the carriage. Fig. 5.5 Removing the Ink Jet Cartridge (6) Remove the protection tape from the new ink jet cartridge. Do not shake the cartridge after the tape has been removed. Fig. 5.
REPAIR SERVICE MANUAL Mechanical (7) Slide the cartridge into the carriage bracket as shown below. Fig. 5.
REPAIR SERVICE MANUAL Mechanical (8) Squeeze the cartridge bracket and cartridge together until the cartridge snaps under the latch on the bracket. Fig. 5.8 Fitting the Cartridge in the Carriage (9) Tile the LCD module into the upright position and at the keyboard press RETURN. The ink jet cartridge is ready to use. (10) Close the LCD module, top cover, and the paper support.
REPAIR SERVICE MANUAL Mechanical 3. Cleaning the Print Head WARNING: The bottom of the ink jet cartridge is covered with wet ink. Avoid contact of ink with skin and clothing. Ink may cause irritation especially to the eyes. 3.1. Cleaning the Print Head Automatically If the ink on the page looks splotchy or smeared, or if blank spaces appear in characters, the print head should be cleaned. To automatically clean the print head, press CODE + SHIFT + INK CHG. 3.2.
REPAIR SERVICE MANUAL 3.3. Mechanical Cleaning the Bracket Contacts (Carriage) (1) Press CODE + INK CHG to move the carriage assembly to the home position (right side). (2) Without turning off the machine, unplug the DC jack from the DC plug connector on the rear of the machine. This will keep the carriage assembly from returning to the maintenance station. (3) Turn the machine off and remove the ink cartridge.
APPENDIX SERVICE MANUAL Specifications APPENDIX A Specifications 1.
APPENDIX SERVICE MANUAL Specifications 2. Printing (1) Printing Method: Lexmark Thermal Ink Jet (2) Heads: Color/Mono (3) Head Type: Thermal Ink Jet (4) Nozzle (mono) 50 active + 6 nozzles (1/300" spots/inch) (5) Head Weight: 74 g maximum (full) 36 g minimum (empty) (6) Ink Color: Black/Color (7) Head Cartridge Set Force: Release Force: 4,000 g maximum 4,000 g maximum (8) Printing Capacity: Max. Paper Width: Max. Printing Width: Possible Printing Area: 241.3 mm (9.5") 205.
APPENDIX SERVICE MANUAL (12) Specifications Auto Cut-sheet Feeder Paper Weight: Paper Thickness: Print Speed: 60 to 90 g/sqm (16 to 24 lb) 0.071 to 0.18 mm (0.0028 to 0.007") LQ: 160 cps; "Ink Saver Mode": 160 cps Paper Set Capacity: Feeder Tray: Paper Tray (stacker): 30 sheets of 20 lb paper 15 sheets of 20 lb paper Performance/Error Ratio: multi-feeds: 1/100 sheets (avg.) jam/misfeed: 1/200 (avg.) Misc. (nick, wrinkle, dogear, etc.): 1/100 (avg.
APPENDIX SERVICE MANUAL Specifications 3. Keyboard (1) Keying System: Conductive-rubber contact (plus Koala 1 actuator system) (2) Construction: PCB: multi-layer printed FPC (single-sheet) Rubber: silicon rubber with conductive Actuator: Koala style with 2 cranks (3) Keystroke: 3.8 mm ± 0.3mm (touch force 300g) (4) Key Touch Load: 60 g ± 20 g (except SPACEBAR: 70 g ± 30 g) (5) Gap between Key Tops & KB Panel: 1.0 mm – 2.0 mm (6) Gap between Key Tops: 0.8 mm – 1.
APPENDIX SERVICE MANUAL 4. Specifications Environmental Tolerance (1) Durability Keyboard cycles: Top cover operation cycles: Paper support operation cycles: LCD cover operation cycles: Paper tray: (2) 1,000,000 times/key 3,000 times 3,000 times 6,000 times 1,500 times Physical Environment Vibration cycles: IMV vibration test machine 5–55 Hz, each direction 0.
APPENDIX SERVICE MANUAL Specifications 5. Dimensions & Weight (1) Dimensions: 16.0(d) × 16.0 (w) × 4.4(h) in. (2) Weight: 11.1 lbs. (5.
R Feb, '98 53T010BE1
